Materials Used in Sea Water System

Materials Used in Sea Water System

Introduction

Material Selection

Sea Water &Corrosion

Titanium Alloys

Composites

Ni Base alloys

Copper alloys
Main use of sea water Industrial Applications

Oil field water injection 1- Shipping

Fire-fighting
2- Offshore

Desalination plants 3- Power plants and

coastal industrial plants

Cooling purpose
4- Oil and gas production
 Causes of Abrupt failures of water cooling system usually
related to:

A- System design

B- Equipment and material selection

- Corrosion - Scales – Fouling

– Biological Proliferations

C- Maintenance
 Main materials used in sea water system

1- Steel alloys (high alloy steel 254 SMO and cast iron ) seawater-cooled
condensers

2- Stainless steel (316 L & duplex stainless) offshore and marine

applications

3- Copper alloys (Cu-Ni& 5% Ni Al bronze) valves and pumps

4- Titanium alloys (Pure Ti &23 (Ti-6Al-4VELI)) offshore and marine

applications

5 - Composite material oil gas and piping

system

6 – Ni – Base alloys Sea water services

 Corrosion data on materials in high velocity test

Alloy Corrosion rate Seawater Velocity

Grey cast Iron 13 38

Carbon steel 9.5 40

Monel Alloy 400 0.010 43

Monel alloy K-500 0.010 43

Stainless steel 0.005 43

 Economic Factors for materials selection

1-A low initial cost system

require considerable maintenance
Carbon steel and Cast iron
over the life of the plant.

Such a system is a reasonable choice in areas where labor costs are low
and material is readily available

2-A high initial cost system

if correctly designed and fabricated, will
Alloy materials require minimum maintenance and will
function reliably

Rising labor costs in most industries and need for high reliability in
capital intensive plant has produced a trend to this type of system
 Seawater piping systems
Minimum first cost - high High reliability - low
maintenance maintenance
cost system Component cost system
Galvanized steel Pipe Copper-base
90-10 Cu-Ni
Steel Flanges - Cast or forged 90-10
Cu-Ni
- Steel welded overlayed
with Cu-Ni
- Gunmetal

60/40 brass/naval brass Tubeplates - Nickel aluminium bronze

- 90-10 Cu-Ni

Aluminium brass Tubes - 70-30 Cu-Ni

(particularly 2% Fe + 2% Mn)
- 90-10 Cu-Ni

Cast iron or leaded Gunmetal Pump casing - Cast Cu-Ni

- Nickel aluminium bronze
- Admiralty Gunmetal
- Ni-resist Type D2

Gunmetal Pump impeller - Monel Alloy 410

- Alloy 20 (CN7M)
- Stainless steel (CF3 and CF8)
- Nickel aluminium bronze

Naval brass Pump shaft - Monel Alloy 400 or 500

- Stainless steel (type 316)
- Nickel aluminium bronze

Cast iron Strainer body - Ni-resist iron type D2

- Nickel Aluminium Bronze
- Cast Cu-Ni
- Gunmetal

Galvanized iron Strainer Monel alloy 400

 Composition of sea water
Component Concentration % of total salt
(mg/l)
Chloride 18,980 55.04
Bromide 65 0.19
Sulfate 2,649 7.68
Bicarbonate 140 0.41
Fluoride 1 0.00
Boric acid 26 0.07
Magnesium 1,272 3.69
Calcium 400 1.16
Strontium 13 0.04
Potassium 380 1.10
Sodium 10,556 30.61
Total 34,482 99.99
 Effect of sea water on corrosion resistance

Chemical Effect Salt Precipitation, Deposits and

Bio-fouling and Sediments Effects
Carbonates and Sulfates
Fouling
Chlorination Effects
Bioforms
pH

Geographical Variations Localized Variations

Temperature Effects Dissolved Oxygen

Velocity Effects Characteristics

Design Effects

Crevice Geometry and Surface

Finish Effects
 Sea water velocity

Corrosion data on materials in high velocity test

Alloy Corrosion rate Seawater Velocity
Grey cast Iron 13 38
Carbon steel 9.5 40
Ni-Cu Alloy 400 0.010 43
Ni-Cu alloy K-500 0.010 43
Stainless steel 316 0.005 43
Gun metal (85/5/5/5) 1.30 40
Nickel Aluminium Bronze 0.80 38-42
 Types of corrosion
Mode of Corrosion Copper Stainless Stainless Steel 6 Titanium
based Steel 316 Mo and Duplex Alloys
alloys
General Corrosion Resistant/Su Resistant Resistant Resistant
sceptible1
Crevice Corrosion Susceptible Susceptible Susceptible (>25ºC) Resistant (<80ºC)2

Pitting Attack Susceptible Susceptible Resistant Immune

Stress Corrosion Susceptible1 Susceptible Resistant Resistant3

(>60ºC)
Corrosion Fatigue Susceptible Susceptible Susceptible Immune

Galvanic attack Susceptible Susceptible Resistant Immune

Microbiological Susceptible Susceptible Susceptible Immune

Corrosion (MIC)
Weld/HAZ Corrosion Susceptible Susceptible Susceptible Resistant

Erosion Corrosion Susceptible Resistant Resistant Highly Resistant

1. Dependent on Pollution level/sea water chemistry

2. Grades 7,11,12, 16,17,20,21,24, 28,29 resistant to at least 200ºC
3. Standard Grade 5 has finite susceptibility, Grade 23 (ELI) has improved K1SCC values
 Titanium alloys

Titanium is as strong as steel, yet 45% lighter. The high strength,

low density and corrosion resistance of titanium contribute
positively towards cost reduction. Weight saving is of great
importance for offshore platforms

Titanium requires no corrosion allowance so equipment can

be designed to satisfy the minimum requirements for
mechanical strength and handling

The number and variety of applications of titanium and titanium alloys

offshore continues to increase. From no more than a few hundreds of kilos
in chlorination systems and heat exchangers twenty years ago, total
consumption now approaches three thousand tons.
Titanium alloys applications in sea water systems

Titanium alloy grade Application

23 (Ti-6Al-4VELI) Taper Stress Joints
23 Drilling Riser
2 (Commercially Pure) Fire Water Systems
2 Sea Water Lift Pipes
2 Ballast Water Systems
2 Anchor System Pipework
2 Penetrations and Manholes
2 Penetration Sleeves
2 Fresh Water Pipework
2 (110 tons) Sea Water Pipework
2 (300 tons) Seawater systems, fire, ballast and
produced water Pipework
2(500 tons) Gravity Based System
9 (Ti-3Al-2.5V) Booster Lines
 Composites
Composites are fast taking over as superior alternative to other
traditional materials even in high pressure and aggressive environmental
situations. Composites have become attractive candidates for
applications in oil gas, piping system, topside applications, down-hole
tubing in sub-sea, and others

Composite piping system Composite handrails and Composite coil tube

grids/gratings
 Composites

Composite Piping System (Glass Reinforced Epoxy (GRE) )

Glass Reinforced Epoxy (GRE) piping system offers complete solution for offshore
environment against highly corrosive fluids at various pressures, temperatures, adverse
soil and weather conditions (especially in oil exploration, desalination, chemical plants,
fire mains, dredging, portable water etc.)

Composite Pressure Risers

Composite riser is the pipeline that connects the rig of the water surface to the well
bore at the seabed

Caissons at offshore
platforms
 Composite material applications
No Application
1 Composite Grids/ Gratings
2 Hand rails & Ladder Components
3 Aqueous Piping System
4 Water & fuel storage tanks, Vessels
5 Low pressure composite valves
6 Spoolable type thermosetting tubes
7 Sump Caissons and pull tubes
8 Cable support systems
9 Modular paneling for partition walls
10 High pressure accumulator bottles
11 Flexible & Floating Risers, Drill pipe
12 Sub – sea structural components
13 Boxes, housings and shelters
14 Fire water pump casing & sea water lift pump casing
15 Tendons
16 Offshore bride connecting between platforms
17 Blast & Fire protection
 Ni Base alloys

Nickel with no other significant alloying elements (UNS NO2200)

readily losing its passivity and suffering pitting and

crevice corrosion. General corrosion rates as high as little used in seawater
8 mpy are possible in polluted seawater.

Chromium-free nickel alloys (UNS NO4400 & UNS NO 10001)

67 nickel- 33 copper (UNS NO4400) and Alloy 400 has been widely
70 nickel - 28 molybdenum (UNS NO 10001) used in seawater
The alloy possesses
Its general corrosion rate in quietly moving excellent resistance to high-
seawater ranges from approximately 0.1- 1.0 mpy. velocity seawater
Care should be exercised when
Pits in alloy 400 tend to self-stifle specifying alloy 400 for thin-wall
products such as exchanger tubes
 Ni Base alloys

Nickel-chromium alloys, with and without molybdenum.

625 (NO6625), alloy C-276 (N10276),

and alloy C-22 (NO6022)
It is considered for seawater
Alloying elements such as, chromium service where there is a potential
and molybdenum make the alloys for crevice corrosion
possess superior crevice corrosion
resistance compared with lesser
alloyed nickel alloys.

Nickel Aluminum Bronze

This alloy has a good combinations of
mechanical properties and corrosion
resistance
It has been used in wide variety of
marine applications including
valves and fittings, ship propellers,
pumps, pump shafts, valve stems
and heat exchanger waterboxes
 Ni Base alloys

Nickel Aluminum Bronze

It has been used in wide

variety of marine applications
This alloy has a good
including valves and fittings,
combinations of mechanical
ship propellers, pumps, pump
properties and corrosion
shafts, valve stems and heat
resistance
exchanger waterboxes
 Copper alloys system in piping
Typical compositions of alloys commonly used in seawater systems

Copper-tin, copper-aluminium and copper-zinc alloys

Nominal composition per cent
Alloy Copper Tin Zinc Aluminium Other
Admiralty
88 10 2 - -
Gunmetal
Leaded
85 5 5 5 -
Gunmetal
Leaded 86 7 2.5 - 2.5% Lead
Gunmetal + 2% Nickel
nickel
Nickel 85 - - 10 5% Iron
aluminium 5% Nickel
bronze
Aluminium 76 22 2 0.02% Arsenic
brass
 Typical compositions of alloys commonly used in seawater systems

Alloys of nickel and copper

Nominal composition per cent

Alloy Copper Nickel Iron Other

90-10 Cu-Ni Remainder 10 1.5 1.0 Mn (max)

70-30 Cu-Ni Remainder 30 0.6 1.0 Mn (max)
70-30 Cu-Ni (high
Remainder 30 2.0 2.0 Mn
iron)
70-30 Cu-Ni+Cr Remainder 30 0.7 1.6 Cr
Ni-Cu Alloy 400 31.5 66 1.35 0.9 Mn
Cast Ni-Cu Alloy
30.5 66 1.35 1.6 Si
BS 3071
Ni-Cu Alloy K 500 31.5 66 1.35 1.9 Mn 2.8 Al
0.5 Ti
Cast Ni-Cu Alloy
29 64 2.0 4.0 Si
BS 3071 NA3
 Copper alloys system in piping

Two copper-base alloys have been widely used for seawater

handling, namely aluminum brass and 90-10 Cu-Ni

When using non-ferrous piping the

system must be designed on the basis of
water velocity in order to avoid
impingement attack

Copper 0.75 m/s

Aluminum
2.5 m/s
brass
Piping
90-10 Cu-Ni 3.0 m/s

70-30 Cu-Ni 3.5 m/s submarine

 Copper alloys system in Piping

The current trend is towards the use of 90-10 Cu-Ni

1- Its better weldability. Although aluminum brass can be welded using aluminum
bronze filler

2- Its high stress corrosion resistance. 90-10 Cu-Ni does not normally require any stress
relief heat treatment after fabrication. Aluminum brass requires stress relief to avoid
the possibility of stress corrosion cracking to which it is susceptible in seawater

3- Its good experience. Some reports showed that, only nine cases of premature
failure over a period of 20 years. This is a remarkable result considering the
large tonnage of the alloy in use throughout the world.
 Copper alloys system in valves

Many corrosion problems in seawater systems occur in

valves. Often such problems are due to the use of steel or cast
iron valves with non-ferrous piping. Although the life of such
valves in a steel or cast iron pipe system is short (i.e., two to
three years) when fitted in a alloy system, it may be less than
a year due to the galvanic effects from the piping.

The three main components of a valve are :

1- The body
2- Valve seats
3- The shafts or stems
 Copper alloys system in valves

1- The body

The basic low cost valve used in ferrous pipe systems has a cast iron body
with 60-40 brass internals. Depending on design, corrosion rates of several
millimeters per year can occur on the body. The body cathodically protects
the internals (until a layer of graphitic corrosion product forms) and the
valve will function for two to three years.

Upgrading of valve body materials to give higher reliability requires the use of
alloys with good corrosion resistance. Such materials are copper base alloys such
as nickel aluminum bronzes, Admiralty and leaded gunmetals and cast Cu-Nis. All
these alloys are characterized by good resistance to static seawater (necessary for
shut-down conditions) and to flowing seawater.
 Copper alloys system in valves

2- Valve seats and stems

The material of Valve seats should have high resistance to fast flowing seawater
such as, stainless steels, nickel-base alloys and Monel alloy 400.

Experience shows that when manufacturers

upgrade the body material they often use the
same materials for seats and stem as in a cast
iron valve, i.e., 60-40 brass. Under these
conditions the life of the valve internals is
extremely short because, having lost the
cathodic protection of the ferrous body, they
fail by dezincification in a few months

Dezincification of a 60-40 brass stem from a bronze valve

 Copper alloys system in valves

Materials for seawater valves in non-ferrous pipe systems

Ball, disc, or Stem
Type of valve Body material
seat material material
Ni-Cu alloys
5% nickel
400 or K500
Gunmetals aluminium
Stainless
5% nickel aluminium bronze bronze
Butterfly steel
Rubber-lined cast iron (provided a Cast 70/30 Cu-Ni
valves (type 316)
seal is fitted at the stem) Cast Monel alloy
5% nickel
Cast 70-30 Cu-Ni Stainless steel
aluminium
(Type 316)
bronze
Globe, gate, or As above, except that rubber lined
As above As above
ball valves valves should be avoided
Not critical
Membrane Rubber as there is
Rubber lined cast iron
valves (membrane) no seawater
content
 INTERACTIONS WITHIN THE SYSTEM

Galvanic Effects
Wherever possible, components of similar galvanic potential should be used for
construction of the system. Where this is not possible, the following guidelines
should be used:

1- Make the "key" component of a more noble material. For example, use copper-base
alloy trim in a cast iron valve body.

2- Ensure that the material of lower potential is present in a much larger area
than the more noble material so that the accelerated corrosion of the anode is
spread over a large area.

3- Paint the more noble material. This can be beneficial as it reduces the cathode
area even when the paint film is incomplete. An imperfect paint film on the
anode would intensify attack at breaks in the paint.
Thank You Very Much